Device and method for automatic generation of control instructions for rotary machines

ABSTRACT

The invention relates to a device and a method for generating control instructions for a rotary machine, wherein processing stations are disposed on a rotary machine. In the preferred embodiment, the processing stations have holders for receiving bottles. Furthermore, gas is supplied via the processing stations and via the pressure management system. The processing stations can be controlled centrally by a PLC, by respectively one separate PLC or by specific microcontrollers. Said components can be programmed by code instructions. A further component of the device is an input and display terminal by which means the programs are created interactively. This is preferably a laptop with a windowed interface such as Windows®. Since rotary machines need to be controlled differently depending on the type of bottles and the type of coating, different programs should be created which then control the individual components of the rotary machine and the processing stations. As a result of the complexity of the control instructions and the associated liability to error in the programming, it is unreasonable for a normal user to create such a program which is generally based on a recipe.

The invention relates to a device and a method for generating controlinstructions for a rotary machine, where processing stations are locatedon a rotary machine, the rotary machine comprises an input and a displayterminal. In particular, the invention relates to a system forgenerating machine codes for PLC (programmable logic controller) andmicrocontrollers which control a rotary machine and its components.

FIELD OF THE INVENTION

Rotary machines such as those to be controlled by the present inventionare used in wide range of applications. The rotary machine shown in FIG.1 is used for coating bottles, especially plastic bottles, with the aidof plasma. The surface of the bottle is coated and the barrier propertyof the surface is thereby modified. Other applications are feasible. Inthe rotary machine, process stations rotate about a central point andcontain bottles. Different process steps are executed depending on therotational position, as can be seen clearly from the Fig.s.

When this device is used for different types of bottles, the control ofthe machines needs to be modified. As a result of the complex PLCcontrol and the microcontroller control, it is unreasonable for a userto produce programs manually.

PRIOR ART

Known programming tools for machine and PLC do not take into account theneeds of the user but primarily have the aim of re-using componentswhich have already been used. Consequently, they are directed towardsthe developers of programs for PLC. Thus, it is feasible that modulesare produced which are then incorporated again at a later point in theform of a library. However, this approach does not solve the saidproblems since it is unreasonable for the user to work at such a lowprogramming level.

It is the object of the invention to provide a device and a methodwhich, by an interactive input of information, makes it possible toautomatically generate a control program which allows the rotary machineto be driven.

OVERVIEW OF THE INVENTION

This object is solved by the invention having the features of theindependent claims. Advantageous further developments of the inventionare characterised in the dependent claims.

In detail, the invention relates to a device and a method for generatingcontrol instructions for a rotary machine, wherein processing stationsare disposed on a rotary machine. In the preferred embodiment, theprocessing stations have holders for receiving bottles. Furthermore, gasis supplied via the processing stations and via the pressure managementsystem. The processing stations can be controlled centrally by a PLC, byrespectively one separate PLC or by specific microcontrollers. Saidcomponents can be programmed by code instructions. A further componentof the device is an input and display terminal by which means theprograms are created interactively. This is preferably a laptop with awindowed interface such as Windows®. Since rotary machines need to becontrolled differently depending on the type of bottles and the type ofcoating, different programs should be created which then control theindividual components of the rotary machine and the processing stations.As a result of the complexity of the control instructions and theassociated liability to error in the programming, it is unreasonable fora normal user to create such a program which is generally based on arecipe.

The invention consequently provides a system which allows the user tocreate a program code for controlling a rotary machine by means ofstructured menu guidance.

In this case, in a first menu level a segment is defined on the rotarymachine using circumferential position parameters. The circumferentialparameters can be numbers of degrees, centimetres on the circumferentialcircle or other equivalent values. In the preferred embodiment these arenumbers of degrees. Thus, a plurality of segments can be defined on therotary machine in which specific functions are then controlled.

The functions of the rotary machine or the processing stations aredetermined in a second menu level which has a reference to thedefinition of the segment in the first menu level. Thus, the circularorbit can be divided into logical segments within which functions arecontrolled. The functions are selected interactively and selectively bymeans of a mask so that the functions within the logical segment arecontrolled. Control instructions in the form of a control code aregenerated on the basis of the logical segmentation thus described andare then transferred to the machine.

In the preferred embodiment the segments are defined by numbers ofdegrees and thereby delimited with respect to one another. The executionof the segments can likewise be determined within the segments bynumbers of degrees which are then added as DELTA to the beginnings ofthe segments and determine the start or stop of the function.

Alternatively, the start or the end of the function within the segmentcan be determined by a time definition such as, for example, a delay.This time unit indicates, for example that the function measured fromthe time of passing through the logical segment is switched on or off oractivated for a certain time unit, the latter being determined directlyfrom the rotational speed.

Furthermore, desired values, warning values and error values for sensorscan be specified within a segment. These data can also be specifiedglobally and used for quality determination, especially for determiningthe rejects and thus serve as the basis for all segments, where the morespecific information in the segment has the higher priority. These arefor example the global machine control parameters: speed, desiredparameters, warning values, error values.

In the preferred embodiment for the coating of bottles, for example, thelocal functions (within the logical segment) and the global functionscan be as follows: valve control, valve monitoring, pump control, pumpmonitoring, microwave control, microwave monitoring, temperaturemonitoring, temperature control, plasma control, plasma monitoring, gascontrol, gas monitoring. Other functions are naturally feasible and areobtained depending on the use of the rotary machine.

After the parameters have now been entered in a structured fashion,these can either be saved as packaged parameter combinations or asfinished codes. The code is generated on the basis of a machine codetemplate, also called a template. This is generally provided withmacro-instructions which are generally replaced by a macro-editor beforethe scan and parser process. The code thus prepared is eitherinterpreted on the rotary machine or it is compiled further before it istransferred to the machine. However, it is feasible that instructionsare modified in the compiled code using a special macro-programidentification. However, this approach is associated with a greatereffort because of the possible address relocations/translation.

After creating the code, this can be transferred to the machine and theindividual controllers.

All these preparatory activities as far as completion of the programcode for the rotary machine and the individual processing stations arepreferably carried out on a PC or laptop. The program fragments thusproduced and code instructions can then be transferred via a networkconnection such as a telephone network for example.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in detail hereinafter with reference toexemplary embodiments shown schematically in the Fig.s. The samereference numbers in the individual Fig.s refer to the same elements. Indetail in the Fig.s:

FIG. 1 is a perspective schematic view of a rotary machine withprocessing stations where not all the processing stations are installed;

FIG. 2 is a schematic diagram of a logical segmentation of a rotarymachine;

FIG. 3 is a screen shot of the global parameter mask;

FIG. 4 is a screen shot of a segment parameter mask.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In one possible embodiment as shown in FIGS. 1 and 2, a rotary coatingsystem 31 comprises twelve processing stations 32 or twelve chambers.The chambers 32 (double reactors) are each provided with respectivelytwo MW generators 33.

The segmentation takes place so that two chambers are always in thecoating phase (17, 18, 19, 20) for the adhesion promoter. Four chambers(9, 10, 11, 12, 13, 14, 15, 16) are always in the coating phase for thebarrier. In the other segments (21, 22, 1, 2) the bottles aretransferred to the machine or leave the machine. In other segments againpump functions are controlled (3, 4, 5, 6). These are connected to thegas generator by means of a ring main. Said gas generator is supplied bya precursor storage container. There is provided a principal evacuatingplant to which each reactor is connected via a manifold. The pressure isregulated centrally at the manifold for the adhesion promoter andbarrier respectively (see FIG. 3).

FIG. 3 shows the adjustment of global recipe parameters; there compriseregulating speed and mass flow regulation. The descriptions areself-explanatory so that no further comment need be made on this withreference to FIG. 1.

FIG. 4 shows the control in a fifth segment which comprises the floodingsegment (17, 18, 19, 20) in relation to FIG. 2. This segment begins at275 degrees. The functions internal aeration and external aeration areactivated and begin with a delay of 80 ms or 150 ms respectively and endafter 25 degrees relative to the beginning of the segment. Flushing gasis then pumped in, this being initiated after a delay of 140 ms and alsobeing initiated so that it covers the segments. Since this involves theend of the segment, the flushing is stopped at the latest when thebottle is ejected.

The scope of protection is determined by the following claims and it isnot intended to be limited by the description.

1. A processing station for generating control instructions for a rotarymachine, wherein processing stations are arranged on a rotary machine,comprising means and a configuration of the means, which an input and adisplay terminal such that the possibility of selecting or determiningsegments on the rotary machine is provided in a first menu level, thatthe function of the rotary machine or the processing stations aredisplayed in a second menu level, with reference to the selectedsegments in the first menu level, wherein the functions can be selectedand their functions can be controlled within the segment, that controlinstructions are generated on the basis of the functions thus definedand their control in the segment.
 2. The processing station according tothe claim 1, comprising means for determining segments by numbers ofdegrees or means for determining functions within the segment by numbersof degrees.
 3. The processing station according to the claim 2,comprising means for determining a first number of degrees whichdetermines the beginning of the segments and comprising means fordetermining a second number of degrees with reference to the functionsin order to determine their beginning within the segment or their endinside the segment.
 4. The processing station according to the claim 1,comprising means for specifying time delay for individual functionswithin the segment.
 5. The processing station according to the claim 1,comprising means for specifying upper limits or lower limits of sensorvalues for a check within the segment.
 6. The processing stationaccording to preceding claim 1, comprising means for specifying globalmachine control parameters valid for all segments.
 7. The processingstation according to the claim 6, wherein the global machine controlparameters are one or more of the following parameters: speed values,desired values, desired ranges, warning values, error values.
 8. Theprocessing station according to the claim 7, wherein the segments areeach defined by their initial value.
 9. The processing station accordingto the claim 1, wherein means and a device are provided to allow thegenerated control instruction to be transmitted online to the rotarymachine or the processing stations.
 10. The processing station accordingto the claim 1, wherein the rotary machine and the processing stationsare provided with means for coating bottles.
 11. The processing stationaccording to the claim 10, wherein means are provided for generatingcontrol instructions for one of more of the following functions: valvecontrol, valve monitoring, pump control, pump monitoring, microwavecontrol, microwave monitoring, temperature monitoring, temperaturecontrol, plasma control, plasma monitoring, gas control, gas monitoring.12. The processing station according to the claim 1, comprising meansfor saving and managing different control instructions or parameters.13. The processing station according to the claim 1, wherein a deviceand means are provided which provide a machine code template for PLC ormicrocontrollers with parameters which have been input via the menulevels and prepare the machine code thus produced as controlinstruction.
 14. The processing station according to the claim 1,wherein the machine code template is a code template which is providedwith the parameters by means of macro-definitions.
 15. The processingstation according to the claim 1, comprising a PC which is programmed sothat it allows parameters to be input via a windowed interface.
 16. Theprocessing station according to the claim 15, wherein the individualsegments are displayed on individual screen pages.
 17. A method forgenerating control instructions for a rotary machine, wherein processingstations are arranged on a rotary machine, comprising an input and adisplay terminal comprising the steps: a) definition of a segment on therotary machine using circumferential position parameters is made in afirst menu level, b) determine a function of the rotary machine or theprocessing stations in a second menu level, with reference to thedefinition of the segment in the first menu level, wherein the functionsare selected interactively and selectively and their functions arecontrolled within the segment, c) generating control instructions in theform of a control code on the basis of the functions thus defined andtheir control in the segment.
 18. The method according to the claim 17,wherein the segments are defined and delimited by numbers of degrees,wherein the execution of the functions within the segment is determinedby the numbers of degrees.
 19. The method according to the claim 18,wherein the control of a function is determined by a second number ofdegrees with reference to the segment in order to determine itsbeginning within the segment or its end within the segment.
 20. Themethod according to the claim 17, wherein time delays for triggering anindividual function within the segment are determined.
 21. The methodaccording to the claim 17, wherein a definition of desired values,warning values and error values is made for sensors within a segment.22. The method according to the claim 17, wherein global machine controlor monitoring parameters valid for all segments are specified.
 23. Themethod according to the claim 22, wherein the global machine controlparameters are one or more of the following parameters: speed, desiredvalues, desired ranges, warning values, error values.
 24. The methodaccording to the claim 17, wherein the control instructions aregenerated for a rotary machine with processing stations, provided withmeans for coating bottles.
 25. The method according to the claim 17,wherein control instructions are generated for one of more of thefollowing functions: valve control, valve monitoring, pump control, pumpmonitoring, microwave control, microwave monitoring, temperaturemonitoring, temperature control, plasma control, plasma monitoring, gascontrol, gas monitoring.
 26. The method according to the claim 17,comprising means for saving and managing different control instructionsor parameters.
 27. The method according to the claim 17, wherein amachine code in which the parameters entered interactively via the menulevels are automatically inserted, is generated on the basis of ageneral machine code template which controls a PLC or a microcontroller.28. The method according to the claim 26, wherein the machine codetemplate is a code template which is provided with the parameters bymeans of macro-definitions of the parameters.
 29. The method accordingto the claim 17, comprising a program code which allows the process torun on a PC.
 30. A data carrier, comprising a data structure which isconstructed so that the process according to the aforesaid method claim17 can be run on a computer and the function of the method is therebyimplemented on the computer.